Lesson Plan Industry Sector

Lesson Plan Originally Created By: Dennis Johnson

Hybrid Safety & Service (updated) by Dennis Johnson

Part of Unit: Green Concepts

Lesson Plan Overview / Details

Students will be exposed to the major parts of a modern gas-electric hybrid drive system.  Most hybrid vehicles conduct almost 600 volts AC and 300 volts DC.  By comparison, the home wall outlet voltage is 120 volts AC.

This lesson will include discussions, modeling, and practice of how to be safe while working on a hybrid vehicle.

Lesson Time

Two Class Periods
55 Minutes

Introduction of Hybrid System

  • Introduce the principles behind the hybrid operation system
  • Identify and locate key components on a hybrid vehicle
  • Safely locate and remove the service plug

Activities in this Lesson

  • As students enter the classroom, they will watch a video clip/animation of a Toyota Prius Hybrid system in action. I will have students write down the key components in the hybrid system. I will give them 5-6 min to complete this activity while role is being taken. After a few minutes I will ask students to describe a few key components.  We will have a group discussion about the video clip to allow students and instructor to share experiences with the class.

    Resources and Materials

  • Instructor will discuss how the hybrid system works, and cover safety while working on the hybrid. This will be done in lecture, hand-outs will be given as well as video clips will be shown.

    The gasoliine-electric hybrid system is also known as "Hybrid Synergy Drive," meaning the vehicle contains a gasoline engine (ICE) internal combustion engine and an electric motor (MG1 & MG2) for power.

                    * Gasoline stored in fuel tank for the ICE

                    * Electricity stored in a high voltage Hybrid Vehicle (HV) battery pack for the electric motor

    Depending on driving conditions, one or both sources are used to power the vehicle.  Students will need to refer to the owner's manual, lecture notes and/or online information system such as ALL-DATA to know where key hybrid components are located.  Instructor will give students two task sheets, one to complete during lecture and one to utilize in the lab. Students will follow along and take notes during this session to use during their own hybrid vehicle inspection and service.

    Resources and Materials

  • Safety First!!  Students will get their safety glasses, rubber gloves, and remove any and all jewlery. Students will bring their sample inspection/identification task sheets, and the two remaining blank inspection sheets and follow the instructor into the lab for demonstration on how to locate key components on a hybrid system. 

    Instructor will demonstrate where to locate the 12 V auxiliary battery, hybrid vehicle (HV) battery pack, electric motor, inverter and gasoline engine (ICE), as well as how to remove the service plug.  Instructor will inform students they should always allow 5 minutes after the plug has been removed before any service is performed to allow all powered modules to time out to prevent accidental electrical shock.


    Once students have observed demonstration on location of key hybrid components, instructor will demonstrate proper procedure for removing the service plug.

    Resources and Materials

  • Instructor will have students gather into groups of (4) four, and assign them a hybrid vehicle, and ask them to complete the task sheet by locating the major hybrid components.

    Once student groups have done this, instructor will ask them to follow the procedures demonstrated to them and have them locate the service plug.  Students will need to determine if this plug is in a safe easily serviceable location.  Instructor will ask them to record their findings on the inspection sheet during this task.  During the inspection and after students have completed their forms, instructor will have students perform spot inspections on the other teams and their work and documentation.

    Resources and Materials

    • Camry_Hybrid_Technician_Worksheets.pdf [ Download ] Component Identification Task Packet
  • Clean Up Closure

    Instructor will have students clean their work area, secure the vehicles, and return any checked out tools and personal safety equipment.  Instructor will discuss the importance of cleaning their work area as well as verify that their work was done and meets industry standards.

    Instructor will discuss the following: Did they get it and can they perform the task?  Instructor will inform students that we will continue with Hybrid safety and service.


Assessment Types:
Demonstrations, Observations,

Instructor will monitor the students during the lecture and ask questions about the material being taught to ensure students understand the information.  Instructor will monitor the students in the lab and ensure they are following shop safety as well as answer any questions that may arise.